Thermoforming process for producing class “A” finish, high gloss automotive exterior parts

ABSTRACT

A thermoforming methodology for laminated thermoplastic sheets which preserves the class “A” finish and high gloss thereof. In a thermoforming process including heating followed by vacuum and opposing air pressure application, and then followed by application of chilled compressed air, control of spherulite formation using any of: addition of a nucleating agent to the paint film, using the chilled compressed air at a temperature of substantially about 32° F., heating to no more than about 311° F., selecting a paint film having a high melting point temperature, and selecting a paint film that is non-crystalline.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part application of application Ser. No. 10/921,514, filed on Aug. 19, 2004 now U.S. Pat. 7,390,454.

TECHNICAL FIELD

The present invention generally relates to methods of thermoforming a laminated thermoplastic sheet, wherein the sheet is capable of achieving a class “A” automotive finish. More particularly, the present invention relates to a thermoforming method which consistently achieves a class “A” finish of a laminated thermoplastic sheet.

BACKGROUND OF THE INVENTION

Automobile fascias, body side moldings (BSM), rockers, etc., are typically produced by an injection molding process followed by painting. The last steps of the painting process require that the painted part be baked for about 30 minutes at, for example, 250° F. This production procedure is proven and functions well. However, there are a number of negatives associated with this process, including: a high scrap rate due to paint defects, expensive tooling costs, burdensome provisions for protection against possible mutilation in handling, and poor stone impact performance in sensitive areas of a motor vehicle (i.e., under highway driving conditions, stones kicked up by other motor vehicles striking certain prone areas of the painted part).

Presently, however, new technologies are developing with the intention of eliminating the high cost of fabricating injection molding tools, and producing parts through the aforementioned injection molding and painting process. These technologies involve, as can be understood by reference to FIG. 1, a laminated thermoplastic sheet 10 which is formed in a thermoforming process. The laminated thermoplastic sheet 10 is composed, for example, of a paint film 12, which may optionally include a paint layer 12 a and a clear coat 12 b, wherein the color, finish and gloss of the class “A” side of the laminated thermoplastic sheet is matched to that of the paint of the motor vehicle to which the laminated thermoplastic sheet is to be used. An optional removable mask 12 c is provided to protect the paint film 12 is removed when the part 20 is completed. The paint film 12 is bonded onto one side of a thermoformable thermoplastic substrate 18, via an adhesive layer 16, wherein the substrate may be, for nonlimiting example, thermoplastic polyurethanes, polyesters, vinyl copolymers, polyvinylchlorides, thermoplastic olefin (TPO), ABS, polyethylene, and blends, copolymers and/or alloys thereof.

Examples of laminated thermoplastic sheets 10 and methods of forming laminated thermoplastic sheets into formed parts 20 are described in U.S. Pat. No. 4,976,896 issued on Dec. 11, 1990 to the assignee hereof, U.S. Pat. No. 4,769,100 issued on Sep. 6, 1988 to the assignee hereof, and U.S. Pat. No. 4,868,030, issued on Sep. 19, 1989 to the assignee hereof; the disclosures of each of said U.S. Pat. Nos. 4,976,896, 4,769,100 and 4,868,030 being hereby herein incorporated by reference. Other U.S. patent references describe additional aspects of laminated thermoplastic sheets and the thermoforming processes therefor, as for example U.S. Pat. Nos. 6,450,793 and 6,709,734 and U.S. Patent Application Publication 2004/0076846.

While the technology for thermoforming laminated thermoplastic sheets has become well established, there yet remains the problem that the thermoforming process adversely affects the gloss of the class “A” finish. For example, the gloss of the class “A” finish may start at a gloss value above 70 but, as a result of thermoforming, the gloss value becomes unacceptably less than 70. Accordingly, in the prior art of thermoforming of laminated thermoplastic sheets, parts have inconsistent finish and gloss, resulting in scrap and/or parts having a finish and/or gloss which does not well match the finish and/or gloss of the paint of conventionally painted surfaces of the motor vehicle.

Thus, there yet remains a need in the art of thermoforming laminated thermoplastic sheets an ability to preserve, reliably under high volume production conditions, the class “A” finish (i.e., the paint film side) of the laminated thermoplastic sheet which well matches the finish of conventionally painted surfaces of a motor vehicle, and retains a gloss value, after thermoforming, of above 70.

The inventors of the present invention have come to the realization that during the processing of the parts, the unique process control required to form a Class “A” part, having critical influence on the gloss of the final part is the absence of spherulite within the paint film.

In the literature, there is reported attempts to control spherulite in PVDF/PMMA blends, as follows.

In the papers “Impact of nucleating agents of PVDF on crystallization of PVDF/PMMA blends”, Polymer 42 (2001), pp. 8799-8806, by S. Schneider, X. Drujon, J. C. Wittman and B. Lotz; and “Self-nucleation and enhanced nucleation of polyvinylidene fluoride (α-phase)”, Polymer 42 (2001), pp. 8787-8798, by S. Schneider, X. Drujon, B. Lotz and J. C. Wittman, the authors discuss the influence of a nucleator to control the size of spherulite size in neat and blended systems. In both of these articles, which articles are hereby herein incorporated by reference, Schneider et al investigate the details of nucleating, but do not demonstrate applicability as is done by this invention.

In the paper “Influence of Additives on the Crystallization Kinetics of Semicrystalline Polymers,” Polymer Engineering and Science, November 2002, Vol. 42, No. 11, by I. Pillin, S. Pimbert and G. Levesque, the authors discuss the influence of organic pigments or mineral fillers and how they influence the non-isothermal crystallization temperatures of PVDF and its blends with PMMA. Again, they discuss the details and specifics of crystallization rate and spherulite formation, but not a method from which to avoid while speeding up the solidification rate without generation of spherulite.

In the paper “Crystallization and Morphology of Melt-Solidified Poly(vinylidene Floride),” from Journal of Polymer Science: Polymer Physics Edition, Vol. 18, pp. 793-809 (1980), by Andrew J. Lovinger, the author discusses the two types of spherulite generated from cooling melted PVDF. The paper simple describes the types of spherulite and how they are generated.

In all the above-referenced papers, it is apparent that the invention is outside the scope of this literature, in that our goal is to prevent or impede formation of spherulite, thus sustaining high gloss.

Accordingly, what remains needed in the art are methods for reducing or eliminating spherulite formation in the paint film of a laminated thermoplastic sheet during a thermoforming process thereof.

SUMMARY OF THE INVENTION

The present invention is a thermoforming methodology for laminated thermoplastic sheets which preserves, reliably under high volume production conditions, the class “A” finish of the laminated thermoplastic sheet which well matches the finish and gloss of conventionally painted surfaces of a motor vehicle, wherein the sheet retains a gloss value, after thermoforming, of above 70, via utilization of any or all of four methods to reduce or eliminate spherulite formation.

The thermoforming process according to the present invention utilizes a thermoforming apparatus including one or more heating stations and a thermoformer. The thermoformer has two mutually separable components: a vacuum box component which includes a mold, and a pressure box component in which chilled, pressurized air is introduced in order to thereby control cooling of the laminated thermoplastic sheet, which controlled cooling results in preservation of the class “A” finish and gloss value above 70.

A laminated thermoplastic sheet, as for example of the type described hereinabove, is loaded, in a conventional manner, onto a frame at a first station of a thermoformer apparatus.

Thereafter, the frame containing the laminated thermoplastic sheet is moved to a heating station, wherein preferably both the class “A” side of the sheet and the opposite class “B” side of the sheet are each heated by respective heater banks. The heater station heats the laminated thermoplastic sheet into a moldably softened state. Optionally, a pre-heat station may be provided.

Next, the laminated thermoplastic sheet is moved into position in the thermoformer, wherein the vacuum box and pressure box components are presently separated from each other, wherein the laminated thermoplastic sheet is disposed between the vacuum box and pressure box components, and wherein the class “A” side of the sheet (i.e., the paint film side) faces toward the pressure box component and the class “B” side of the sheet (i.e., the substrate side) faces toward the mold of the vacuum box component.

Now, the vacuum box and pressure box components are mutually closed together, whereby the perimeter surfaces thereof mutually engage to provide an air-tight seal therebetween.

Once the perimeters of the vacuum box and pressure box components mutually seal, a cooling line in the mold is activated, and a vacuum (by “vacuum” is meant air pressure below atmospheric pressure) is applied to the vacuum box side of the laminated thermoplastic sheet, causing the class “B” side of the sheet to be sucked formingly onto the surface of the mold, and simultaneously compressed air (by “compressed air” is meant air under pressurization above atmospheric pressure) is forced into the pressure box component at the class “A” side of the laminated thermoplastic sheet, causing the sheet to be pressed formingly onto the surface of the mold.

As soon as the laminated thermoplastic sheet has formed onto the surface of the mold, the compressed air is vented as chilled compressed air (by “chilled compressed air” is meant compressed air at a temperature below substantially 70° F.) is continuously flushed into the pressure box. The chilling of the chilled compressed air can be provided, for example, by a refrigeration and/or a throttling process. The chilled compressed air cools the laminated thermoplastic sheet in a rapid and controlled manner which is critical to preservation of finish and gloss of the class “A” side thereof. Alternatively, the chilled compressed air can be used throughout the forming and cooling processes.

Critical to the success of forming a class “A” part is the rate of cooling of the class “A” side of the laminated thermoplastic sheet. The class “A” side temperature needs to be reduced to less than 190° F. as fast as possible, as for example within 30 seconds of initial forming of the sheet on the mold, more preferably within 20 seconds, and most preferably within 15 seconds. An infrared temperature sensor is used to indicate the class “A” side temperature of the laminated thermoplastic sheet.

Once the part is formed of the laminated thermoplastic sheet, the vacuum box and pressure box components are again separated, and the formed laminated thermoplastic sheet is removed, in a conventional manner from the mold. Next, the formed thermoplastic sheet is moved to a next station where it is removed, in a conventional manner, from the frame, put onto a cooling fixture, and then moved to a trimming station which trims it so as to provide a completed part.

According to the foregoing process, the thermoforming of laminated thermoplastic sheet consists of a heating step, a forming step, and a cooling step. The laminated thermoplastic sheet used for producing high gloss durable parts is composed of a poly(vinylidene fluoride)/poly (methylmethacrylate) (PVDF/PMMA) blend paint film containing a paint layer and a clear coat bonded onto one side of a thermoplastic substrate. With the materials currently being used, the high gloss retention is obtained only with careful control of the paint film thermal history. In particular, the paint film cannot be excessively heated, i.e., it should be kept under about 330° F., more preferably under about 311° F., and must be cooled, as for example via chilled compressed air. When the minimum paint film temperature is not maintained or an insufficient cooling rate occurs, spherulite form in the paint film. This spherulite formation scatters light and results in poor gloss retention.

The present invention particularly involves methods to reduce the size, eliminate, and/or minimize of spherulite formation in and on the surface of the paint film of the laminated thermoplastic sheet. These methods can be divided into either adjusting the composition of paint film or adjusting the thermoforming process, itself. These methods, which may be individually utilized or utilized in any combination, include:

1) Addition of a nucleating agent to the paint film. Nucleating agents can reduce the size and eliminate spherulite formation, so that by adding a nucleating agent spherulite formation is controlled, which in turn improves gloss retention.

2) Increase the cooling rate of the thermoplastic sheet. Since spherulite formation is time and temperature dependent, faster cooling will inhibit spherulite formation and improves gloss retention.

3) Reduce the thermoforming temperature. As mentioned above, since spherulite formation is time and temperature dependent, by operating at a lower forming temperature spherulite formation will be eliminated and gloss retention improved.

4) Utilize a paint film having a higher melting point surface. Spherulite formation usually requires melting, therefore a film with a higher melting point will be less prone to spherulite formation and thus have better gloss retention. In the case of PVDF/PMMA paint films the melting point increases with PVDF concentration. Films with higher PVDF contentions would therefore be less prone to spherulite formation and have better gloss retention. The higher PVDF content need not be throughout the entire paint film, but is required on the surface.

Accordingly, it is an object of the present invention to eliminate the injection molding fabrication and painting process by providing a laminated thermoplastic thermoformed part having a class “A” finish and having a preserved gloss value above 70.

This and additional objects, features and advantages of the present invention will become clearer from the following specification of a preferred embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a broken-away, sectional side view of a prior art thermoformed part, the part being conventionally thermoformed from a conventional laminated thermoplastic sheet.

FIG. 2 is a flow chart of thermoforming steps according to the method of the present invention.

FIGS. 3A through 3G are schematic views depicting a series of sequential steps of the method of FIG. 2.

FIGS. 4A and 4B are schematic views depicting an alternative embodiment of the thermoformer of FIGS. 3C through 3G.

FIG. 5 is a plot of melting point temperature of a paint film versus PMMA concentration.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the Drawing, FIGS. 2 through 4B depict various aspects of the thermoforming process 100 according to the present invention. In this regard, FIG. 2 depicts the thermoforming process 100 as a block flow chart 102, and FIGS. 3A through 4B depict schematic views of various steps of the flow chart of FIG. 2.

At Block 102 of the block flow chart 100, a laminated thermoplastic sheet 200 (see FIGS. 3A through 4B) is provided and loaded, in a conventional manner, onto a frame at a first station of a thermoformer apparatus, which may be, for example, configured for rotational loading, sled loading, or other form of loading.

The laminated thermoplastic sheet 200 may, for example, be of the type described hereinabove. By way merely of preference and not limitation, the thermoplastic carrier sheet of the laminated thermoplastic sheet 200 may have the following specifications: the composition is a thermoplastic olefin (TPO) material, having a stock thickness ranging between 40 and 400 thousandths of an inch, more preferably between 60 and 180 thousandths of an inch, and most preferably between 100 and 160 thousandths of an inch. Further by way merely of preference and not limitation, the paint film of the laminated thermoplastic sheet 200 may have the following specifications: the paint film is laminated to the thermoplastic carrier sheet, and consists of a PVDF/PMMA dispersion with color matched to specific vehicle paint; a mask is incorporated with composition primarily of polyurethane, commonly referred to as a “Version 14” or a “Version 8” available, for example through Soliant, LLC. of Lancaster S.C. 29720. Other paint films and/or masks are usable.

At Block 106, the laminated thermoplastic sheet 200 is moved, via the frame, into one or more heating stations, preferably including (see FIGS. 3A and 3B) an optional pre-heating station 202 at Block 106 a and a main heating station 204 at Block 106 b, wherein the pre-heating station, when present, provides partial heating to the sheet in advance of the main heating station. Preferably, both the class “A” side A of the sheet and the opposite class “B” side B of the sheet are each heated by respective heater banks 206 ap, 206 bp, 206 am, 206 bm. The heaters of the heater banks may be, for example, quartz, calrod, ceramic, halogen, or combinations thereof. The main heater station 204 heats the laminated thermoplastic sheet 200 into a moldably softened state so that it is ready for being thermoformed.

If Block 106 a is utilized, wherein pre-heating of the laminated thermoplastic sheet 200 is provided at the pre-heating station 202, then the sheet is heated thereat for between about 1 and 3 minutes to attain a sheet temperature of about 250° F. Thereupon, the laminated thermoplastic sheet 200 is shuttled to the main heating station 204.

At Block 106 b, the laminated thermoplastic sheet 200 is heated in the main heating station 204 preferably as follows. The class “B” side B of the sheet is spaced from heater bank 206 bm a distance between preferably 7 inches and 24 inches and is heated to about 400° F. The class “A” side A of the sheet is spaced from heater bank 206 am a distance preferably between 12 inches and 32 inches. The laminated thermoplastic sheet 200 is heated for a period of time of preferably between 1 and 5 minutes or until the class “A” side A of the sheet attains a temperature ranging from between about 280° F. and 350° F., more preferably between about 290° F. and 330° F., and yet more preferably between about 300° F. and 315° F. The heater bank temperature is controlled by an infrared sensor indicating the temperature of the class “A” side A of the sheet.

At Block 108 the heated laminated thermoplastic sheet 200 is delivered, via the frame, to a thermoformer 208 (see FIG. 3C). The thermoformer 208 has two components which are mutually separable and sealable: a vacuum box component 210 and a pressure box component 212. In this regard, it is preferred for the laminated thermoplastic sheet 200 is oriented such that the class “A” side A thereof faces toward the pressure box component 212, and the class “B” side B thereof faces toward the mold surface 224.

The vacuum box component 210 includes a vacuum box wall 214 which defines a vacuum box 230, a selectively movable inner support, a selectively movable mold 218, and a vacuum source 220 connected to the vacuum box via a vacuum conduit 222 which passes through the vacuum box wall. The mold 218 is, for example, composed of poured aluminum which is cut back to size, surface treated and sand blasted, and includes a mold surface 224 of a predetermined shape to which the laminated thermoplastic sheet 200 is to be formingly shaped. The mold further has a plurality of coolant lines 228 through which a liquid coolant flows, wherein the coolant lines may be in multiple zones, preferably between two and four zones, for cooling the mold surface. The vacuum source is preferably capable of providing a vacuum of at least 30 inches of mercury (inches of Hg) as fast as possible, for example within between about 60 seconds and less than 10 seconds, more preferably in less than 10 seconds.

The pressure box component 212 includes a pressure box wall 240 which defines a pressure box 260, a source of compressed air 242, an air valve 244, an air chiller 246, an air port 262 at the pressure box wall, an air pressure regulation valve 264, which may be incorporated with a dump valve 248, in the pressure box wall, and, preferably, an auxiliary source of compressed air 250, an auxiliary air valve 252 and an auxiliary air port 254 at the pressure box wall. The air chiller 246 cools the compressed air exiting from the source of compressed air 242, and may, for nonlimiting example, be a refrigeration device (as for example an air conditioning unit and/or a heat exchanger) 246 a and/or a throttling valve 246 b for cooling by the well-known Joule-Thomson effect in which rapid expansion of a gas produces cooling thereof. The dump valve 248 is preferably in the form of a 4 inch air actuated ball valve. The source of compressed air 242 and the auxiliary source of compressed air 250 are preferably capable of providing a high cubic foot per minute air flow at a pressure of at least 50 pounds per square inch above atmospheric pressure (psi). In this regard, the airflow rate of the chilled compressed air is sufficient to maintain a predetermined chilled temperature, discussed hereinbelow, within the pressure box.

The vacuum box and pressure box components 210, 212 are movable toward and away from each other, preferably the vacuum box component being stationary, wherein when in a mutually separated state, as shown at FIGS. 3C and 3G, the laminated thermoplastic sheet is movable into and out of the thermoformer 208, and wherein when in a mutually closed state, the mutual perimeters 214 p, 240 p of the vacuum box wall 214 and the pressure box wall 240, respectively provide an air tight seal therebetween.

Operation of the aforementioned components is preferably controlled by a programmable microprocessor Mp, shown at FIG. 2.

Returning to Block 108, at FIG. 3D the vacuum box and pressure box components 210, 212 are bought together into the aforementioned closed state, whereat the perimeters 214 p, 240 p provide an air tight seal therebetween inclusive of the laminated thermoplastic sheet 200. With the laminated thermoplastic sheet 200 still in the aforementioned heated state provided by Block 106, thermoforming of the sheet is then performed at the thermoformer 208, as follows.

At Block 108 a, cooling liquid (as for example water) is circulated through the coolant lines 228.

Next, at Block 108 b, the vacuum source 220 is activated, drawing down a vacuum in the vacuum box 230 of from between zero and 30 inches of Hg, more preferably of between 10 and 25 inches of Hg, and most preferably of between 18 and 22 inches of Hg as fast as possible, for example within between about 60 seconds and less than 10 seconds, more preferably in less than 10 seconds. As shown sequentially at FIGS. 3D and 3E, the vacuum causes the laminated thermoplastic sheet 200 to be sucked onto the mold surface 224 and thereupon assume the shape of the mold surface.

Simultaneously with execution of Block 108 b, at Block 108 c the auxiliary air valve 252 is opened and the auxiliary source of compressed air 250 thereupon delivers compressed air CA to the pressure box 260 of the pressure box component 212. The auxiliary source of compressed air 250 provides a rapid pressurization in the pressure box 260 of between zero to 40 psi, more preferably of between 5 and 30 psi, and yet more preferably between 10 and 25 psi. The pressure of the compressed air CA in the pressure box 260 is regulated by the pressure regulation valve 264, which may be incorporated in the air valve 244, in the auxiliary air valve 252, in the dump valve 248 (as mentioned and shown merely by way of example) or be a separate pressure regulation valve in the pressure box wall 240.

As shown sequentially at FIGS. 3D and 3E, the pressure of the compressed air CA pressing the laminated thermoplastic sheet 200 onto the mold surface 224 simultaneously acts with the sucking action of the vacuum source 220 drawing the laminated thermoplastic sheet onto the mold surface in Block 108 b, to thereby enhance the forming detail of the laminated thermoplastic sheet with respect to surface details of the mold surface. The pressure of the compressed air CA at Block 108 c is held in the pressure box 260 for between zero and 40 seconds, more preferably for between 5 and 30 seconds, and yet more preferably for between 7 and 15 seconds.

Once the aforesaid time of pressurization at Block 108 c has expired, the auxiliary source of compressed air 250 is shut off by the auxiliary air valve 252 being closed and the dump valve 248 being opened so as to dump the compressed air CA from the pressure box, as shown at FIG. 3E, to environs outside the thermoformer 208.

Next, at Block 108 d, the dump valve 248 is closed and chilled compressed air CCA is introduced into the pressure box, via opening of the air valve 244, to allow, as shown at FIG. 3F, compressed air from the compressed air source to pass through the air chiller 246 flushingly into the pressure box 260. The pressure value of the chilled compressed air CCA is basically the same as that indicated hereinabove for the compressed air CA. The chilled compressed air CCA flushes at a flow rate into and out of the pressure box 260 so that, at maintained pressure, the temperature of the chilled compressed air in the pressure box is maintained at between 32 and 70° F., more preferably between 32 and 60° F., and yet more preferably between 32 and 50° F.

The chilled compressed air CCA is applied for between 1 and 15 seconds, more preferably between 5 and 10 seconds, the time being determined by the desire to chill the class “A” side A of the laminated thermoplastic sheet 200 to a temperature of 200° F., more preferably to below 190° F., wherein an infrared temperature sensor senses the temperature of the class “A” side of the sheet, and the microprocessor controls the rate of temperature lowering of the sheet to ensure retention of gloss of the class “A” side thereof. In this regard, critical to the success of forming a class “A” part is the rate of cooling of the class “A” side (or surface) A of the laminated thermoplastic sheet 200. The class “A” side temperature needs to be reduced to less than 190° F. as quickly as possible, for example within 30 seconds of initial forming on the mold, more preferably within 20 seconds and still more preferably within 15 seconds. Once forming of the laminated thermoplastic sheet is completed, the air valve 244 is closed.

At Block 110, the laminated thermoplastic sheet 200 has fully formed on the mold surface and has now become cooled, whereupon, as shown at FIG. 3G, the vacuum box and pressure box components 210, 212 are again separated, so that the formed laminated thermoplastic sheet 200′ can be removed from the thermoformer 208.

Once the formed laminated thermoplastic sheet is removed from the thermoformer, it is moved to a next station where it is removed, in a conventional manner, from the frame, put onto a cooling fixture, and then moved to a trimming station which trims it to size to provide a completed part at Block 112.

While the above-described method of thermoforming involved an auxiliary source of compressed air 250, it is possible to alternatively use the source of compressed air 242 as a singular source of compressed air to the pressure box, as for example depicted at FIGS. 4A and 4B. In this regard, the air from the source of compressed air 242 may be chilled through the air chiller 246 initially as the singular source of compressed air 242 supplies at all times chilled compressed air to the pressure box 260, as shown at FIG. 4A (in this case, the compressed air comprises chilled compressed air). Alternatively in this regard, an initial shot of compressed air may be delivered as described hereinabove using only the source of compressed air 242, wherein a switch valve 244′ directs the compressed air initially through an alternate conduit with a port 254′, then after the laminated thermoplastic sheet has initially formed, the switch valve directs the compressed air through the refrigeration device 246 to provide the chilled compressed air at the portal 262′ in the manner described hereinabove, as shown at FIG. 4B.

Utilizing the aforedescribed thermoforming process 100 according to the present invention, a laminated thermoplastic sheet can be thermoformed into a part with a retained gloss above 70 and distinctness of image (DOI) greater than 80, the requirement for class “A” parts for automotive industry.

The following examples were performed and are provided for illustrative purposes. Gloss was measured using a BYK-Gardner (of Columbia, Md. 21046) micro tri-gloss meter model 4524 at a 60 degrees surface angle. In each example, the laminated thermoplastic sheet was a TPO sheet having a composition similar to that shown in FIG. 1, and having a total thickness of about 140 thousandths of an inch.

EXAMPLE 1

PROCESSING CONDITIONS: VALUES: Class “A” side temp. 330 degrees F. Class “B” side temp. 430 degrees F. Compressed air temp. Not applicable Chilled compressed air temp. Not applicable Air pressure in pressure box None Vacuum 20 inches of Hg Vacuum time about 60 seconds Mold coolant temp. 75 to 90 degrees F. 60° gloss reading before molding at or above 70 60° gloss reading after molding 50 Mold cooling temperature 75 to 90 degrees F. Quality of part, comments Webbing, poor quality, lost gloss

Example 1 illustrates prior art thermoforming process conditions, wherein the hoped for outcome should a high gloss class “A” part; however, poor part quality and low gloss resulted. There was no compressed air in the pressure box.

EXAMPLE 2

PROCESSING CONDITIONS: VALUES: Class “A” side temp. 320 degrees F. Class “B” side temp. 420 degrees F. Compressed air temp. about 90 degrees F. Chilled compressed air temp. Not applicable Air pressure in pressure box 20 psi Compressed air time about 60 seconds Vacuum 20 inches of Hg Vacuum time about 60 seconds Mold coolant temp. 75 to 90 degrees F. 60° gloss reading before molding at or above 70 60° gloss reading after molding 50 Mold cooling temperature 75 to 90 degrees F. Quality of part, comments poor forming, lost gloss

Example 2 illustrates a second example of the prior art which is an adjustment of the process illustrated in Example 1, wherein ambient temperature compressed air was introduced into the pressure box. Although temperatures were lowered, the results were as in Example 1, poor part quality and low gloss.

EXAMPLE 3

PROCESSING CONDITIONS: VALUES: Class “A” side temp. 310 degrees F. Class “B” side temp. 400 degrees F. Compressed air temp. about 90 degrees F. Chilled compressed air temp. 70 degrees F. Air pressure in pressure box 20 psi Compressed air time 7 to 12 seconds Chilled compressed air time 53 to 48 seconds Vacuum 20 inches of Hg Vacuum time about 60 seconds Mold coolant temp. 75 to 90 degrees F. 60° gloss reading before molding at or above 70 60° gloss reading after molding 60 Mold cooling temperature 75 to 90 degrees F. Quality of part, comments good forming, lost gloss

In Example 3, by adding some chilled compressed air into the pressure box, the definition of the formed part was improved, but the gloss was still inferior.

EXAMPLE 4

PROCESSING CONDITIONS: VALUES: Class “A” side temp. 310 degrees F. Class “B” side temp. 400 degrees F. Compressed air temp. about 90 degrees F. Chilled compressed air temp. 50 degrees F. Air pressure in pressure box 20 psi Compressed air time 7 to 12 seconds Chilled compressed air time 53 to 48 seconds Vacuum 20 inches of Hg Vacuum time about 60 seconds Mold coolant temp. 75 to 90 degrees F. 60° gloss reading before molding at or above 70 60° gloss reading after molding at or above 70 Mold cooling temperature 75 to 90 degrees F. Quality of part, comments good forming, retained gloss

Example 4 was carried out according to the thermoforming method 100 of the present invention, as outlined hereinabove. The forming detail and retention of gloss of the class “A” side was excellent.

EXAMPLE 5

The process as described above in Example 4 was followed, but the class “A” side of the laminated thermoplastic sheet was cooled such that the class “A” side did not reach 190 degrees F. within 15 seconds. By not switching to chilled air for greater than 15 seconds, the gloss of the part was reduced to less than a value of 70. This illustrates the importance of cooling the class “A” side of the laminated thermoplastic sheet below 190 degrees F. within 15 seconds. Not achieving this timing causes the gloss of the class “A” side to fall below 70.

By contrast, the process as described in Example 4 involved the chilled compressed air being introduced in less than 7 to 12 seconds into the pressure box, resulting a gloss value being retained above 70. Accordingly, it is anticipated that incorporating the chilled compressed air initially at the pressurization stage will further enhance or sustain the final gloss of the class “A” side of the laminated thermoplastic sheet.

According to the foregoing process, the thermoforming of laminated thermoplastic sheet consists of a heating step, a forming step, and a cooling step. The laminated thermoplastic sheet used for producing high gloss durable parts is composed of a poly(vinylidene fluoride)/poly (methylmethacrylate) (PVDF/PMMA) blend paint film containing a paint layer and a clear coat bonded onto one side of a thermoplastic substrate. With the materials currently being used, the high gloss retention is obtained only with careful control of the paint film thermal history. In particular, the paint film cannot be excessively heated, ie., it should be kept under about 330° F. and more preferably under about 311° F., and must be cooled, as for example via chilled compressed air. When the minimum paint film temperature is not maintained or an insufficient cooling rate occurs, spherulite form in the paint film. This spherulite formation scatters the light and results in poor gloss retention.

The present invention particularly involves methods to reduce the size, eliminate, and/or minimize of spherulite formation in and on the surface of the paint film of the laminated thermoplastic sheet. These methods, which may be utilized singly or utilized collectively in any combination, can be divided into either adjusting the composition of paint film or adjusting the thermoforming process, itself.

In a first method, a nucleating agent is added to the paint film. Nucleating agents can reduce the size and/or eliminate spherulite formation. Thus, adding a nucleating agent controls spherulite formation, which in turn helps gloss retention during and after the thermoforming process.

EXAMPLE 6

Nucleating Cooling 60° Gloss 60° Gloss Agent mode before heating after heating Spherulite No Room 75 31 Yes temperature Diameter > air 5 microns No Ice water 76 72 No Yes Room 76 60 Yes temperature Diameter ≦ air 2 microns Yes Ice water 77 70 No

In Example 6, a PVDF/PMMA laminated thermoplastic sheet was heated to 373 degrees F. The nucleating agent was a red tint pigment of a particle size less than one micron. Examples of nucleating agents include sodium benzoate, benzoic acid, etc., wherein criteria for choice of nucleating agent are: contains both an organic and a polar group; well dispersed in the polymer; insoluble or can become insoluble in the polymer; has an epitaxial match with the polar crystal; and chemically reacts with the polymer, wherein the chemical reaction product nucleates the polymer; and the diversity of the physical and chemical attributes include: impurity (as for example a catalyst residue), or color pigment; an organic compound, as for example benzoic acid; an inorganic compound, as for example talc or a pigment; and a foreign polymer crystal. It is clearly seen that the presence of nucleating agents provides a reduction of spherulite formation, and consequently, a better gloss retention.

A second method is to make the cooling rate rapid. Spherulite formation is time and temperature dependent. Thus, a rapid cooling of the thermoplastic sheet inhibits spherulite formation and improves gloss retention. In this regard, cooling is preferably between substantially 5 and 20 seconds using chilled air (although not preferred, the time can be reduced to one second or less if quenching is performed by ice water) from the paint film thermoforming temperature, as for example between about 311° F. and about 330° F.

EXAMPLE 7

Cooling 60° Gloss 60° Gloss mode before heating after heating Spherulite Room 75 31 Yes temperature air Ice water 76 72 No

In Example 7, a PVDF/PMMA laminated thermoplastic sheet was heated 373° F. It is clearly seen that the rapid cooling provided by ice water immersion, as opposed to room temperature air blowing, provided a reduction of spherulite formation, and consequently, a better gloss retention.

A third method is to limit hotter forming temperatures. As mentioned with respect to the second method, spherulite formation is time and temperature dependent. Thus, by keeping the temperature of the paint film lower, spherulite formation will be eliminated and gloss retention will be improved. In this regard, merely by way of illustration, the thermoforming temperature of the substrate may be between about 400° F. and 440° F.; the melt temperature of the paint film may be on the order of about 380° F.; and the thermoforming temperature of the paint film may be between about 311° F. and 330° F. It was found that a higher paint film thermoforming temperature of about 330° F. produced little to no spherulite if all four of the methods herein were collectively utilized.

EXAMPLE 8

Cooling 60° Gloss 60° Gloss Temperature mode before heating after heating Spherulite 351° F. Room 76 36 Yes temperature air 331° F. Room 76 74 No temperature air

In Example 8, it is clearly seen that providing a lower forming temperature provides a reduction of spherulite formation, and consequently, a better gloss retention.

A fourth method is to utilize a paint film having a relatively higher melting point as compared to the thermoforming temperature imparted to the paint film. Spherulite formation usually requires melting; therefore, a paint film with a higher melting point, it will be less prone to spherulite formation and thus have better gloss retention

Self-nucleation in PVDF/PMMA paint films has been investigated in the art, as for example described in “Self-nucleation and enhanced nucleation of polyvinylidene flouride (α-phase)”, by S. Schneider, X. Drujon, B. Lotz and J. C. Wittmann, Polymer Vol. 42, pp. 8787-8798, Elsevier Science, Ltd., (2001). In this paper, it is indicated that the addition of PMMA to PVDF reduces the melting point, and performance is optimized when the PVDF content is above 50 percent, wherein a 70/30 blend (30 percent PMMA) is optimal for physical and optical properties.

Thus, in the case of PVDF/PMMA paint films, the melting point increases with PVDF concentration. Paint films with higher PVDF concentration would, therefore, be less prone to spherulite formation and have better gloss retention, as exemplified by plot 300 of FIG. 5. The higher PVDF content need not be throughout the entire paint film, but is only required on the surface.

Examples thereof include where the PVDF/PMMA ratios are increased, such that it approaches a value of 1. The higher PVDF ratio raises melting point, but also increases spherulite formation due to high PVDF concentration. It is the balance between compositions and forming process control that results in a high gloss Class “A” finish.

To those skilled in the art to which this invention appertains, the above described preferred embodiment may be subject to change or modification. Such change or modification can be carried out without departing from the scope of the invention, which is intended to be limited only by the scope of the appended claims. 

1. A method for controlling spherulite formation during thermoforming a laminated thermoplastic sheet, wherein the thermoforming comprises the steps of: a) heating the laminated thermoplastic sheet, wherein the laminated thermoplastic sheet has a first side and an opposite second side, wherein the first side comprises a class “A” paint film having an initial gloss; b) placing the heated laminated thermoplastic sheet into a thermoformer, wherein the thermoformer has a mold surface and wherein the second side of the laminated thermoplastic film faces toward the mold surface; c) cooling the mold surface; d) applying vacuum to the thermoformer, wherein the vacuum acts suckingly upon the second side of the laminated thermoplastic sheet; and e) applying chilled compressed air having a temperature less than 70 degrees F to the thermoformer during the step d), wherein the chilled compressed air acts pressurably upon the first side of the laminated thermoplastic sheet; wherein the vacuum and the chilled compressed air act on the laminated thermoplastic sheet to cause the laminated thermoplastic sheet to conform to a shape of the mold surface; and wherein the chilled compressed air causes the laminated thermoplastic sheet to cool at a rate which preserves the initial gloss of the class “A” paint film; said method for controlling spherulite formation comprising at least one step selected from the group of steps consisting of: aa) adding a nucleating agent to the paint film prior to step a); bb) performing step e) using the chilled compressed air at a temperature of substantially between 32 degrees F and 50 degrees F; cc) performing step a) such that the paint film of the laminated thermoplastic sheet is kept below substantially between 311 degrees F and 330 degrees F; and dd) selecting the paint film, prior to step a), such that the paint film has a high melting point temperature relative to a temperature imparted to the paint film in step a).
 2. The method of claim 1, wherein said method for controlling spherulite formation comprises selecting all of said steps aa) through dd).
 3. The method of claim 2, wherein in said step cc) the paint film of the laminated thermoplastic sheet is kept below substantially 330 degrees F.
 4. The method of claim 1, wherein said step dd) comprises selecting a ratio of poly(vinylidene fluoride) to poly(methylmethacrylate) of at least fifty percent poly(vinylidene fluoride).
 5. The method of claim 4, wherein said method for controlling spherulite formation comprises selecting all of said steps aa) through dd).
 6. The method of claim 5, wherein in said step cc) the paint film of the laminated thermoplastic sheet is kept below substantially 330 degrees F.
 7. The method of claim 5, wherein said step dd) comprises selecting a ratio of poly(vinylidene fluoride) to poly(methylmethacrylate) of substantially seventy percent poly(vinylidene fluoride).
 8. The method of claim 7, wherein said method for controlling spherulite formation comprises selecting all of said steps aa) through dd).
 9. The method of claim 8, wherein in said step cc) the paint film of the laminated thermoplastic sheet is kept below substantially 330 degrees F.
 10. A method for controlling spherulite formation during thermoforming a laminated thermoplastic sheet, wherein the thermoforming comprises the steps of: a) heating the laminated thermoplastic sheet, wherein the laminated thermoplastic sheet has a first side and an opposite second side, wherein the first side comprises a class “A” paint film having an initial gloss; b) placing the heated laminated thermoplastic sheet into a thermoformer, wherein the thermoformer has a mold surface and wherein the second side of the laminated thermoplastic film faces toward the mold surface; c) cooling the mold surface; d) applying vacuum to the thermoformer, wherein the vacuum acts suckingly upon the second side of the laminated thermoplastic sheet; e) applying compressed air to the thermoformer substantially simultaneously with the step d), wherein the compressed air acts pressurably upon the first side of the laminated thermoplastic sheet; and f) applying chilled compressed air having a temperature less than 70 degrees F to the thermoformer after the step e) and during the step d), wherein the chilled compressed air acts pressurably upon the first side of the laminated thermoplastic sheet; wherein the vacuum and the chilled compressed air act on the laminated thermoplastic sheet to cause the laminated thermoplastic sheet to conform to a shape of the mold surface; and wherein the chilled compressed air causes the laminated thermoplastic sheet to cool at a rate which preserves the initial gloss of the class “A” paint film; said method for controlling spherulite formation comprising at least one step selected from the group of steps consisting of: aa) adding a nucleating agent to the paint film prior to step a); bb) performing step e) using the chilled compressed air at a temperature of substantially 32 degrees F; cc) performing step a) such that the paint film of the laminated thermoplastic sheet is kept below substantially 311 degrees F; and dd) selecting the paint film, prior to step a), such that the paint film has a high melting point temperature relative to a temperature imparted to the paint film in step a).
 11. The method of claim 10, wherein said method for controlling spherulite formation comprises selecting all of said steps aa) through dd).
 12. The method of claim 11, wherein in said step cc) the paint film of the laminated thermoplastic sheet is kept below substantially 330 degrees F.
 13. The method of claim 10, wherein said step dd) comprises selecting a ratio of poly(vinylidene fluoride) to poly(methylmethacrylate) of at least fifty percent poly(vinylidene fluoride).
 14. The method of claim 13, wherein said method for controlling spherulite formation comprises selecting all of said steps aa) through dd).
 15. The method of claim 14, wherein in said step cc) the paint film of the laminated thermoplastic sheet is kept below substantially 330 degrees F.
 16. The method of claim 13, wherein said step dd) comprises selecting a ratio of poly(vinylidene fluoride) to poly(methylmethacrylate) of substantially seventy percent poly(vinylidene fluoride).
 17. The method of claim 16, wherein said method for controlling spherulite formation comprises selecting all of said steps aa) through dd).
 18. The method of claim 17, wherein in said step cc) the paint film of the laminated thermoplastic sheet is kept below substantially 330 degrees F. 